Modular building panel

ABSTRACT

An improved prefabricated modular building panel includes a three-dimensional lattice fabricated of a plurality of rod-like slender elongated metal elements. The lattice elements are arranged to define a pair of substantially parallel spaced major lattice surfaces, and side and end lattice edge surfaces. A plurality of strut members traverse the interior of the lattice and interconnect the major surfaces to define a plurality of passages within the lattice. The passages are open at at least one end thereof to one of the lattice edge surfaces. Thermal insulating filler material is disposed within the lattice and extends from side to side and from end to end of the lattice. The filler material includes a plurality of insulative elements positioned in the passages through the passage open ends to be disposed wholly within the lattice. A bonding agent is used to secure the insulative elements in position within the lattice, and the bonding preferably is a layer of foam material applied over the insulative elements within the lattice to foam at least partially in situ and to bond to the insulative elements and to the metal elements of the lattice, particularly the lattice strut members.

United States Patent 11 1 Weismann i 1 MODULAR BUILDING PANEL [76]Inventor: Victor P. Weismann 430 Prospect Cir., South Pasadena. Calif9l030 [22] Filed: May 3i, i973 [2|] Appl. N0.: 365,538

Related US. Application Data [63] Continuation of Scr. No. 202.879. Nm:2). i971.

OTHER PUBLICATIONS Architectural Record. July 1960. pp. 224.

Primary Examiner-lohn E. Murtagh Attorney. Agent. or FirmChristie.Parker & Hale II/II, 1/1/11. 'IIII'I/I/I/I 7/111 917/1 Apr. 29, 1975[57] ABSTRACT An improved prefabricated modular building panel includesa three-dimensional lattice fabricated of a plurality of rod-likeslender elongated metal elements. The lattice elements are arranged todefine a pair of substantially parallel spaced major lattice surfaces,and side and end lattice edge surfaces. A plurality of strut memberstraverse the interior of the lattice and interconnect the major surfacesto define a plurality of passages within the lattice. The passages areopen at at least one end thereof to one of the lattice edge surfaces.Thermal insulating filler material is disposed within the lattice andextends from side to side and from end to end of the lattice. The fillermaterial includes a plurality of insulative elements positioned in thepassages through the passage open ends to be disposed wholly within thelattice. A bonding agent is used to secure the insulative elements inposition within the lattice. and the bonding preferably is a layer offoam material applied over the insulative elements within the lattice tofoam at least partially in situ and to bond to the insulative elementsand to the metal elements of the lattice. particularly the lattice strutmembers.

6 Claims. 6 Drawing Figures MODULAR BUILDING PANEL This is acontinuation of application Ser. No. 202,879, filed Nov. 29, I971, nowabandoned.

FIELD OF THE INVENTION The invention pertains to improvements in modularbuilding panels. More particularly, it pertains to building panelshaving a three-dimensional wire lattice within which is disposed acomposite insulative core comprised of insulative elements inserted intothe interior of the lattice and a bonding agent securing the insertedelements in fixed position within the lattice.

BACKGROUND OF THE INVENTION Review of the Prior Art My prior U.S. Pat.Nos. 3,305,991 and 3,555,131 describe a reinforced modular foam buildingpanel and methods for fabricating such a panel, respectively. The panelis a composite of a welded three-dimensional wire lattice and of aninsulative core defined by a quantity of cellular foamed material foamedand hard-set in the lattice to bond to the strut members which traversethe interior of the lattice. The strut members interconnect andreinforce the wire elements defining the two spaced major surfaces ofthe lattice. Panels in accord with the disclosures of these patents havebeen approved for use by the International Conference of BuildingOfficials, Pasadena, Calif. Report No. 2440, as structural ornon-structural roof and wall panels for commercial and residentialconstruction. These panels are characterized by their light weight, goodthermal, moisture and acoustic insulative properties, their adaptabilityto efficient erection procedures, their compatibility with conventionalconstruction techniques, and their strength. The strength of these priorpanels is obtained in part from the intimate bonding relation betweenthe foamed-insitu core of the panels to the strut members of the wirelattice.

For many applications, however, it has been found that panels fabricatedaccording to U.S. Pat. No. 3,305,991, for example, so far exceed therequirements of the application that they may not be a practicalalternative to other more conventional construction materials. Forexample, in warm or tropical areas where a structure need not bedesigned to withstand snow loads or the like, these prior panels arestronger and more insulative than is necessary. Also, in some instances,notably in the case of foreign markets and special usages, suitableinsulation materials and elements may exist which are equally well orbetter suited to the particular application than the foam materialscontemplated by my prior patents and which may be more attractiveeconomically. In view of these factors, a need exists for modularbuilding panels which have the general advantages of my prior panels,such advantages deriving in large part from the wire lattice, but whichincorporate insulative cores different from those encountered in panelsfabricated pursuant to my prior patents. Satisfaction of this need willenhance the utility and usage of my prior panels and will make possiblethe use of improved construction techniques in many geographic andfunctional areas where the prior panels cannot or are not being used tobest advantage.

SUMMARY OF THE INVENTION This invention fills the need described aboveby providing improvements in reinforced welded-wire lattice modularbuilding panels. The present panels possess all of the advantages foundin my prior panels due to the presence of the lattice therein. Thepresent panels, however, incorporate insulative core elements andmaterials which may differ from those of my prior panels to adapt thepresent panels to particular applications or to take advantage ofparticular economic and supply situations. The present panels are light,strong, simple to use in construction, efficient and economical.

Generally speaking, this invention provides a prefabricated modularbuilding panel which includes, as a principal component, athree-dimensional lattice fabricated of a plurality of slender elongatedmetal elements. These elements are arranged to define a pair ofsubstantially parallel spaced major lattice surfaces, and side and endlattice edge surfaces. The metal elements include a plurality of strutmembers which traverse the interior of the lattice and interconnect thelattice major surfaces. The strut members and the other elements of thelattice are arranged to define a plurality of passages within thelattice which open at at least one end thereof to the lattice edgesurfaces. Thermal insulation filler material is disposed within thelattice and extends substantially from side to side and from end to endof the lattice. The filler material includes a plurality of insulativeelements which are positioned in the lattice passages through the openends of the passages to be disposed wholly within the lattice. A bondingagent interconnects the insulative elements to the adjacent latticeelements, notably the strut members, to secure the insulative elementsin position in the lattice.

DESCRIPTION OF THE DRAWINGS The above-mentioned and other features ofthis invention are more fully set forth in the following description ofcertain presently preferred embodiments of the invention, whichdescription is presented with reference to the accompanying drawings,wherein:

FIG. I is a perspective view of a portion of a panel according to thisinvention;

FIG. 2 is a cross-section view taken along line 22 in FIG. 1;

FIG. 3 is a cross-section view taken along line 3-3 in FIG. 2;

FIG. 4 is a view similar to that of FIG. 2 but of another panel;

FIG. 5 is a transverse cross-section view of another panel; and

FIG. 6 is a transverse cross-section view of another panel.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS As shown in FIG. I, theprincipal components of a building panel 10 are a lattice 11 and a core12 of insulative filler material disposed within the lattice. Thelattice is defined by a plurality of elongate, slender rodlike metalelements. Conveniently, the lattice may be made of elements defined bywire having a size of from 8 to 16 gage, inclusive, and preferably theelements of the lattice are defined by l4 gage wire. Preferably, thesame size wire is used throughout lattice 11, but it is within the scopeof this invention that the wires used to define one group of elements ofthe lattice may be of a different size, within the preferred rangementioned above, from the elements defining the remainder or differentgroups of elements within the lattice.

The lattice includes a plurality of spaced parallel upper longitudinalelements 13 which are conveniently referred to as upper truss runners. Acorresponding plurality of spaced parallel lower longitudinal elements14 define lower truss runners. The upper truss runners 13 areinterconnected by a plurality of spaced parallel transverse members 15,and the lower truss runners 14 are interconnected by a correspondingplurality of transverse members 16. The upper truss runners and theircorresponding transverse members define an upper major surface of panel10. Similarly, the lower truss runners and their transverse membersdefine a lower major surface of the lattice. These major surfaces arespaced apart in substantially parallel relationship to each other by aplurality of strut members 17 which traverse the interior of the latticeand interconnect the lattice major surfaces.

As shown most clearly in FIG. 1, it is preferred that the upper andlower truss runners be disposed in pairs in which one upper truss runnerl3 and one lower truss runner 14 are disposed in parallel spacedalignment with each other. Strut members 17 preferably areinterconnected between the upper and lower truss runners in each alignedpair thereof rather than being interconnected between transverse membersand 16. Accordingly, a plurality of parallel passages 18 are definedwithin the interior of lattice 11 between the lattice major surfaces andbetween adjacent pairs of truss runners as interconnected by the strutmembers. Each passage 18 is open at at least one end to one of thelattice edge surfaces. Preferably the passages extend along the lengthof the lattice and open at their opposite ends to the end surfaces ofthe lattice.

In a presently preferred lattice, truss elements 13, 14, I5 and 16 arespaced apart from each other on 2 inch centers within their respectivegroups. Also, it is preferred that the aligned upper and lower trussrunners be spaced apart on 2 inch centers. Accordingly, lattice 11 isorganized on a 2 inch cubicle module and conveniently is fabricated in 4foot widths and in lengths of from 8 to 14 feet, the length varyingwithin this range in 2 inch increments. It will be appreciated, however,that different spacing of the elements of lattice 11 may be used asdesired and that the lattice may be fabricated with different nominalwidth or length, all without departing from the scope of this invention.

Each upper truss runner 13, its corresponding lower truss runner 14, andthe strut members 17 which interconnect them define a truss sectionwithin lattice 11. Because of the above-mentioned 2 inch spacing betweenadjacent ones of truss runners l3 and I4, respectively, it is apparentthat the truss sections are spaced apart from each other in parallelrelationship on 2 inch centers across the width of lattice 11. Eachpassage 18 longitudinally through lattice 11 is defined between anadjacent pair of truss sections 20.

FIGS. 2 and 4 illustrate, respectively, two different styles of trusssections which may be used to advantage in the lattice for a panelaccording to this invention. Truss section 20, shown in FIG. 2, ischaracterized in that strut members 17, located within the ends of thetruss section, are disposed in alternate converging and divergingrelationship to each other along the length of the truss section. Thatis, one strut member may slope at about a 45 angle from left to rightproceeding upwardly from lower truss runner 14 to upper truss runner 13,and the next strut member to the right may slope from left to rightproceeding downwardly from upper truss runner 13 to lower truss runnerl4, and so on throughout the length of the truss section. At each end oftruss section, however, an end strut member 22 is provided and isdisposed perpendicular to the adjacent truss runners. ln lattice 11, orin any other lattice according to this invention, it is preferred thatthe various elements defining the lattice be interconnected viaresistance welding, although other interconnection techniques may beused if desired. Where the truss sections in the lattice have theconfiguration shown in FIG. 2, in which strut members 17 are alternatelyinclined to each other, it is preferred that the converging ends ofstrut members 17 be interconnected to the truss runners on oppositesides of and spaced from alternate ones of the transverse membersassociated with that truss runner. That is, if an adjacent pair of strutmembers 17 converge toward each other at the upper truss runner 13, thenthe upper ends of these strut members are interconnected to the uppertruss member in somewhat spaced relationship from and on opposite sidesof one of upper transverse members 15; it is preferred that a lowertransverse member 16 be disposed directly below this upper transversemember. Proceeding along the length of the truss section, however, thenext upper transverse member 15 lies between the diverging ends ofa pairof strut members which have their lower ends interconnected to lowertruss runner 14 close to and on opposite sides of the next lowertransverse member 16.

FIG. 4 illustrates another truss section 23 for use in a lattice for apanel according to this invention. As to truss section 23, however, thestrut members are identifed as 17 to distinguish them from thealternately converging and diverging strut members of truss section 20.Strut members 17' are all disposed parallel to each other perpendicularto upper and lower truss runners 13 and 14 in each truss section 23. Itis preferred that, if lattice elements 13, 14, 15 and 16, respectively,are spaced apart upon 2 inch centers within their corresponding groups,then strut members 17' are spaced apart on I inch centers along thelength of each truss section 23. As a practical matter, theconfiguration of truss section 20 is preferred over the configuration oftruss section 23 since truss section 20 requires the use of a smalleramount of lattice wire stock than does truss section 23 to define alattice of comparable strength. That is, to define lattices ofequivalent structural properties, about 40 percent more lattice wirestock must be used to define strut members 17' of truss section 23 thanis required to define strut members 17 of lattice section 20.

Regardless of whether truss sections 20, 23, or some other truss sectionconfiguration is used in the definition of a lattice for a panelaccording to this invention, it is preferred that the truss sections bedefined as subassemblies of the lattice, which subassemblies are theninterconnected by transverse members 15 and 16, for example, to definethe completed lattice.

1n the manufacture of panel 10, for example, it is preferred thatinsulative core 12 be installed within the lattice after the lattice hasbeen fabricated. The core of a panel according to this invention iscomposed of a plurality of discrete insulative elements which areinserted into the lattice one to each passage 18 through the open endsof the passages. A suitable bonding agent is then applied to theinserted insulative elements to connect the inserted insulative elementsto the lattice structure, thereby to secure the insulative elements inthe desired relationship to one another within the lattree.

In panel 10, core 12 is defined by a plurality of strips of polystyrenefoam 25, which are shown best in FIG. 3. Polystyrene is prefoamed todefine strips of the appropriate length, width and thickness. or thestrips 25 are cut from a board of polystyrene foam to the desired sizeprior to insertion of the strips into passages 18 of lattice 11. Inpanel 10, each strip 25 has a width which approximates the spacingbetween the adjacent surfaces of the strut members of the truss sectionswhich bound opposite sides of passages 18. Strips 25 have a thicknesswhich is substantially less than the spacing between the upper and lowermajor faces of lattice 11. For example. strips 25 may have a width justslightly less than 2 inches so that they may be inserted into passages18, and have a thickness on the order of about three-fourths inch. Inpanel 10, the strips are inserted into passages 18 to be disposed withinthe passages parallel to and substantially midway between the majorfaces of the lattice. The inserted polystyrene foam strips aremaintained in this position while a suitable bonding agent 26 isdisposed. preferably by spraying, over at least one side of the array ofstrips 25. The bonding agent hardens to secure the strips in theirpredetermined positions within lattice 11. In panel l0, the bondingagent preferably is a polyurethane foam which is deposited over theupper surfaces of the array of inserted strips 25 to foam in situ and tocure to a hardened state. thereby to bond the inserted insulativeelements to the adjacent portions of lattice 11. It is preferred thatfoam layer 26 be formed to a thickness which is less than the spacingbetween the substantially coplanar upper surfaces of insulative elements25 and the upper major surface of lattice ll.

FIG. 4 illustrates that the precise nature of the insulative core for apanel according to this invention is not dependent upon the use of aparticular type of truss section in the lattice of the panel.Accordingly. FIG. 4 illustrates a panel 27 in which the lattice 28thereof includes truss sections 23, but in which core 12 is identical tothe core of panel 10, illustrated in FIGS. 1, 2 and 3.

FIG. 6 is a fragmentary transverse cross-sectional elevation view ofanother panel 30 according to this invention. Panel 30 includes alattice 11, which may include truss sections or 23, as desired. Panel 30has an insulative core 31 which is defined by elongate pieces of rigidfoam material 32, one of which is inserted into each passage 18 providedwithin the lattice. Each inserted insulative element 32 for panel 30 hasa crosssectional configuration which corresponds closely to thecross-sectional configuration of each passage 18 so as to substantiallyfill passage 18. In the case of panel 30, a layer 33 of bonding agent isdeposited over the surfaces of elements 32 which are exposed to theopposite major faces of the lattice. Bonding agent 33 may be provided inthe form of liquid latex or latex-base material applied to the insertedinsulative elements to cure and thereby produce the desired bond of theinsulative elements to the lattice elements, notably the strut membersof the lattice. Preferably, the core, comprised of the insertedinsulative elements and the bonding agent. is disposed essentiallywholly within the lattice of the completed panel and does notsignificantly embed the lattice elements defining the major and edgesurfaces of the lattice.

Another panel 40 according to this invention is shown in FIG. 5 andincludes a lattice 11. Panel 40 has an insulative core 41 which iscomposed of a plurality of hollow paper tubes 42, preferably treated ontheir interior surfaces to be water impermeable. and a quantity ofpolyurethane foam 43. for example. disposed over those exterior surfacesof tubes 42 which lie adjacent the major surfaces of the lattice.Preferably tubes 42 are of an elliptical shape and are configured sothat in the normal state of the tubes the major diameter of the ellipseis slightly greater than the width of lattice passages 18, and in whichthe minor diameter of the ellipse is less than the distance between thespaced major surfaces of the lattice. Tubes 42 may be held in positionin their respective lattice passages following insertion of the tubesinto the lattice by interferring mechanical engagement between the tubesand the strut members of the lattice prior to application of the liquidpolyurethane foam material. The foam material is deposited over theexterior surfaces of the tubes in such a condition that the foammaterial foams in situ within the lattice and cures to a hardened orsemi-hardened state to embed the strut members and secure tubes 42 inposition within the lattice.

The accompanying drawings illustrate that the cores for the panels ofthis invention may be disposed wholly within the confines of the latticeof the corresponding panel; this disposition of the insulative corewholly within the panel lattice is the preferred relationship of thecore to the lattice. It is within the scope of this invention. however.that the insulative core may. if desired. extend outside the lattice andembed the lattice elements defining one or both of the lattice majorsurfaces. but preferably not any of the lattice edge surfaces. Themanufacture ofa panel in which one or both of the lattice major surfacesis embedded by the insulative core of the panel is particularly possiblewhere the bonding agent is a foam material which is susceptible of beingfoamed and hardened in situ. i.e.. within the panel lattice rather thanin a separate foaming chamber. For example. the manufacture of apolystyrene foam requires that the constituents of the foam material befoamed in a closed mold. Polyurethane foam, on the other hand, may befoamed and set in an open mold at ambient temperature and pressureconditions. Accordingly. where a foam material is used as the bondingagent to secure the inserted insulative elements of the core in positionwithin the panel lattice. the foam bonding agent must be of the typewhich may be foamed in an open container.

In the preceding description. reference has been made to specificmaterials for use as inserted insulative elements ofthe panel core andalso to specific materials which may be used as the bonding agent in thecore. As is apparent from the foregoing description. the bonding agentitself may contribute to the insulative properties of the core. as inthe case where the bonding agent is foamed in situ urethane foam. forexample. Other foams which can be used either solely or in combinationwith other foam materials to define the inserted insulative elements ofthe core are phenolic foam, expanded vinyl foam. cross-linked polyvinylchloride foam. low density polyethylene foam. crosslinked polyethylenefoam, and ureaformaldehyde foam. All of these foams are of the typewhich require formation in a closed. or at least partially closed mold.and therefore may be used to advantage in a panel ac cording to thisinvention only to define the inserted insulative elements. Materialsother than foams. such as balsa wood, may be used to define the insertedinsulative elements of the panel. Other bonding agents which may be usedto advantage in the fabrication of a panel according to this inventioninclude foamed plaster. asphalt or asphalt-based materials. or suitableadhesives such as epoxy system adhesives.

Urethane foams are preferred as the bonding agent to secure the insertedinsulative elements within the lattice of a panel fabricated accordingto this invention. Also. rigid urethane foams may be used to define theinserted insulative elements. Urethane foams possess several importantproperties. notably good insulating efficiency. light weight. strength.and adhesion in the in situ situation. When a urethane foam is used asthe bonding agent. it is particularly desirable because it structurallybonds itself securely to the inserted insulative elements and to theadjacent members of the panel lattice. Polystyrene foams. on the otherhand. cannot be used to advantage as a bonding agent in a panelaccording to this invention since polystyrene foams can not be foamed inan open container. Polystyrene foams are somewhat less expensive thanurethane foams and have thermal and acoustical insulating propertieswhich closely approach those of polyurethane foam.

If desired. a panel according to this invention may be formed with anopening to conveniently receive a window or door assembly.

In erecting a structure. such as a dwelling. from pan els provided bythis invention, extremely simple tech niques may be used. The panels arefirst aligned with each other with the edges abutting. Since the latticemembers of the panels are exposed at the edges of the panels. or arejust barely covered by the bonding agent used in the fabrication of thepanel. adjacent panels may be wired or welded together by very simpleand economical techniques. In such a manner. the entire external andinternal wall system of a building. as well as the roof of the building,may be erected by one or two men in an extremely short time.

The panels of this invention are characterized by their light weight.Preferably the panels weigh no more than about 2 pounds per cubic footof panel. The exact weight per unit volume of the panel would bedependent upon the gage of wire used in the fabrication of the panel andthe precise nature of the materials used to define the panel core.

While this invention has been described above in conjunction withspecific panels and materials constituting the same, it is to beunderstood that this has been by way of describing certain presentlypreferred embodiments of the invention and is not intended as alimitation of the scope of this invention.

What is claimed is:

l. A prefabricated modular building panel as an article of manufacturecomprising a three-dimensional lattice fabricated of a plurality ofslender elongated metal elements arranged to define a pair ofsubstantially parallel spaced major lattice surfaces, side and endlattice edge surfaces. and a plurality of strut members traversing theinterior of the lattice and interconnecting the major surfaces thereofto define a plurality of passages within the lattice open at at leastone end thereof to one of the edge surfaces. and thermal insulatingfiller material disposed within the lattice to extend from side to sideand from end to end of the lattice. the filler material being held inposition within the lattice by the elements defining the lattice. thefiller material being comprised of a plurality of insulative elementspositioned in the passages through the open ends of the passages to bedisposed wholly within the lattice and sized relative to the passages tomake substantial positioning contact with the lattice elements definingthe respective passages whereby the insulative elements are held inpredetermined positions within the lattice by the lattice itself. and abonding agent disposed between the insulative elements and the adjacentlattice elements for immovably fixing the insulative elements in saidpredetermined positions within the lattice. wherein the bonding agent iscomprised of a layer of cellular foamed material foamed at least in partand at least partially hard set within the lattice.

2. A panel according to claim 1 wherein the bonding agent comprisespolyurethane foam material.

3. A prefabricated modular building panel as an article of manufacturecomprising a three-dimensional lattice fabricated ofa plurality ofslender elongated metal elements arranged to define a pair ofsubstantially parallel spaced major lattice surfaces, side and endlattice edge surfaces. and a plurality of strut members traversing theinterior of the lattice and interconnecting the major surfaces thereofto define a plurality of passages within the lattice open at at leastone end thereof to one of the edge surfaces. and thermal insulatingfiller material disposed within the lattice to extend from side to sideand from end to end of the lattice. the filler material being held inposition within the lattice by the elements defining the lattice. thefiller material being com prised of a plurality of insulative elementsdefined by a rigid cellular foam material positioned in the passagesthrough the open ends of the passages to be disposed wholly within thelattice. and a bonding agent disposed between the insulative elementsand the adjacent lattice elements for fixing the insulative elements inposition within the lattice.

4. A panel according to claim 3 wherein the foam material is a syntheticnon-cementitious foam material.

5. A panel according to claim 4 wherein the foam material is polystyrenefoam.

6. A prefabricated modular building panel as an article of manufacturecomprising a three-dimensional lattice fabricated of a plurality ofslender elongated metal elements arranged to define a pair ofsubstantially parallel spaced major lattice surfaces. side and endlattice edge surfaces. and a plurality of strut members traversing theinterior of the lattice and interconnecting the major surfaces thereofto define a plurality of passages within the lattice open at at leastone end thereof to one of the edge surfaces, and thermal insulatingfiller material disposed within the lattice to extend from side to sideand from end to end of the lattice, the filler material being held inposition within the lattice by the elements defining the lattice. thefiller material being comprised of a plurality of insulative elementspositioned in the passages through the open ends of the passages to bedisposed wholly within the lattice and sized relative to the passages tomake substantial positioning contact with the lattice elements definingthe respective passages whereby the insulative elements are held inpredetermined positions within the lattice by the lattice itself. and abonding agent disposed between the insulative elements and the adjacentlattice elements for immovably fixing the insulative elements in saidpredetermined positions within the lattice, the bonding agent beingcomprised of a latex base material.

1. A prefabricated modular building panel as an article of manufacturecomprising a three-dimensional lattice fabricated of a plurality ofslender elongated metal elements arranged to define a pair ofsubstantially parallel spaced major lattice surfaces, side and endlattice edge surfaces, and a plurality of strut members traversing theinterior of the lattice and interconnecting the major surfaces thereofto define a plurality of passages within the lattice open at at leastone end thereof to one of the edge surfaces, and thermal insulatingfiller material disposed within the lattice to extend from side to sideand from end to end of the lattice, the filler material being held inposition within the lattice by the elements defining the lattice, thefiller material being comprised of a plurality of insulative elementspositioned in the passages through the open ends of the passages to bedisposed wholly within the lattice and sized relative to the passages tomake substantial positioning contact with the lattice elements definingthe respective passages whereby the insulative elements are held inpredetermined positions within the lattice by the lattice itself, and abonding agent disposed between the insulative elements and the adjacentlattice elements for immovably fixing the insulative elements in saidpredetermined positions within the lattice, wherein the bonding agent iscomprised of a layer of cellular foamed material foamed at least in partand at least partially hard set within the lattice.
 2. A panel accordingto claim 1 wherein the bonding agent comprises polyurethane foammaterial.
 3. A prefabricated modular building panel as an article ofmanufacture comprising a three-dimensional lattice fabricated of aplurality of slender elongated metal elements arranged to define a pairof substantially parallel spaced major lattice surfaces, side and endlattice edge surfaces, and a plurality of strut members traversing theinterior of the lattice and interconnecting the major surfaces thereofto define a plurality of passages within the lattice open at at leastone end thereof to one of the edge surfaces, and thermal insulatingfiller material disposed within the lattice to extend from side to sideand from end to end of the lattice, the filler material being held inposition within the lattice by the elements defining the lattice, thefiller material being compriSed of a plurality of insulative elementsdefined by a rigid cellular foam material positioned in the passagesthrough the open ends of the passages to be disposed wholly within thelattice, and a bonding agent disposed between the insulative elementsand the adjacent lattice elements for fixing the insulative elements inposition within the lattice.
 4. A panel according to claim 3 wherein thefoam material is a synthetic non-cementitious foam material.
 5. A panelaccording to claim 4 wherein the foam material is polystyrene foam.
 6. Aprefabricated modular building panel as an article of manufacturecomprising a three-dimensional lattice fabricated of a plurality ofslender elongated metal elements arranged to define a pair ofsubstantially parallel spaced major lattice surfaces, side and endlattice edge surfaces, and a plurality of strut members traversing theinterior of the lattice and interconnecting the major surfaces thereofto define a plurality of passages within the lattice open at at leastone end thereof to one of the edge surfaces, and thermal insulatingfiller material disposed within the lattice to extend from side to sideand from end to end of the lattice, the filler material being held inposition within the lattice by the elements defining the lattice, thefiller material being comprised of a plurality of insulative elementspositioned in the passages through the open ends of the passages to bedisposed wholly within the lattice and sized relative to the passages tomake substantial positioning contact with the lattice elements definingthe respective passages whereby the insulative elements are held inpredetermined positions within the lattice by the lattice itself, and abonding agent disposed between the insulative elements and the adjacentlattice elements for immovably fixing the insulative elements in saidpredetermined positions within the lattice, the bonding agent beingcomprised of a latex base material.